Adaptation of feed rate for 3-axis CNC high-speed machining

To improve the efficiency of CNC machining, assumptive transit circular arc is used to contour two adjacent moves together on the comer to make smooth paths. The radios of transit circular arc can be adjusted with contour accuracy, and the feed rate on the corner can be controlled through limiting the maximum feed rate of transit circular arc segment. A look-ahead algorithm for a series of moves is proposed for speed adjustment in advance, which avoids the occurrence of overload of cutting tool on the comer and reduces the servo track error of parts on the corner or of circular arc move. Equivalent trapezoidal velocity profile is used to analyze the speed of S-curve velocity profile and work out its accurate interpolation, which overcomes the disadvantage of looking up table to calculate feed rate approximately, hence high accuracy and fine surface quality can be obtained while the machining speed is high. The proposed methods can meet the requirements of real-time analysis of high-speed machining. The presented algorithm is effective and has been adopted by CNC system of newly developed high-speed milling machine.

INTERNET-BASED MACHINING PARAMETER OPTIMIZATION AND MANAGEMENT SYSTEM FOR HIGH-SPEED MACHINING

The theory and its method of machining parameter optimization for high-speed machining are studied. The machining data collected from workshops, labs and references are analyzed. An optimization method based on the genetic algorithm (GA) is investigated. Its calculation speed is faster than that of traditional optimization methods, and it is suitable for the machining parameter optimization in the automatic manufacturing system. Based on the theoretical studies, a system of machining parameter management and optimization is developed. The system can improve productivity of the high-speed machining centers.

Development of High-speed Machining Database with Case-based Reasoning

Applying high-speed machining technology in shop floor has many benefits, such as manufacturing more accurate parts with better surface finishes. The selection of the appropriate machining parameters plays a very important role in the implementation of high-speed machining technology. The case-based reasoning is used in the developing of high-speed machining database to overcome the shortage of available high-speed cutting parameters in machining data handbooks and shop floors. The high-speed machining database developed in this paper includes two main components: the machining database and the case-base. The machining database stores the cutting parameters, cutting tool data, work pieces and their materials data, and other relative data, while the case-base stores mainly the successfully solved cases that are problems of work pieces and their machining. The case description and case retrieval methods are described to establish the case-based reasoning high-speed machining database. With the case retrieval method, some succeeded cases similar to the new machining problem can be retrieved from the case-base. The solution of the most matched case is evaluated and modified, and then it is regarded as the proposed solution to the new machining problem. After verification, the problem and its solution are packed up into a new case, and are stored in the case-base for future applications.

An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path

A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.

Pre-Compensation for Continuous-Path Running Trajectory Error in High-Speed Machining of Parts with Varied Curvature Features

Parts with varied curvature features play increasingly critical roles in engineering, and are often machined under high-speed continuous-path running mode to ensure the machining efficiency. However, the continuous-path running trajectory error is significant during high-feed-speed machining, which seriously restricts the machining precision for such parts with varied curvature features. In order to reduce the continuous-path running trajectory error without sacrificing the machining efficiency, a pre-compensation method for the trajectory error is proposed. Based on the formation mechanism of the continuous-path running trajectory error analyzed, this error is estimated in advance by approximating the desired toolpath with spline curves. Then, an iterative error pre-compensation method is presented. By machining with the regenerated toolpath after pre-compensation instead of the uncompensated toolpath, the continuous-path running trajectory error can be effectively decreased without the reduction of the feed speed. To demonstrate the feasibility of the proposed pre-compensation method, a heart curve toolpath that possesses varied curvature features is employed. Experimental results indicate that compared with the uncompensated processing trajectory, the maximum and average machining errors for the pre-compensated processing trajectory are reduced by 67.19% and 82.30%, respectively. An easy to implement solution for high efficiency and high precision machining of the parts with varied curvature features is provided.

Serrated chip characteristics and formation mechanism in high-speed machining of selective laser melted Ti6Al4V alloys

Serrated chips,consisting of extremely uneven plastic deformation,are a prominent feature of high-speed machining of difficultto-machine materials.This paper focuses on the evolution of chip form,chip morphology features(chip free surface,tool-chip contact surface,and chip edge),and chip segment parameters in subsequent high-speed(vc=50 and 150 m min-1)machining of selective laser melted(SLMed)Ti6Al4V alloys,which are significantly different from conventional Ti6Al4V alloy in microstructure,mechanical properties and machinability.The effect of laser beam scanning schemes(0°,67.5°,and 90°),machined surfaces(top and front),and cutting speeds on serrated chip characteristics of SLMed Ti6Al4Valloys was investigated.Based on the Johnson-Cook constitutive model of SLMed Ti6Al4Valloys,an orthogonal cutting model was developed to better understand the effect of physical-mechanical properties on the shear localization,which dominates the formation mechanism of serrated chips in post-machining of SLMed Ti6Al4V alloy.The results showed that the critical cutting speed(CCS)for chip serration of SLMed Ti6Al4V alloy is lower than that for serrated chips of conventional Ti6Al4V alloy,and the serrated profile of SLMed Ti6Al4V chips was more regular and pronounced.Besides,due to anisotropic microstructure and mechanical properties of SLMed Ti6Al4Valloys,the serration degree of chips produced on the top surfaces of SLMed Ti6Al4Valloys is more prominent than that of chips generated on the front surfaces.In addition,because of the poor deformation coordination and high plastic flow stresses of needle-like martensiteα′,the plastic flow and grain distortion in the adiabatic shear band(ASB)of SLMed Ti6Al4V chips are significantly smaller than those in the ASB of conventional Ti6Al4V with equiaxed grains.

Numerical Study on Reduction in Aerodynamic Drag and Noise of High-Speed Pantograph

Reducing the aerodynamic drag and noise levels of high-speed pantographs is important for promoting environmentally friendly,energy efficient and rapid advances in train technology.Using computational fluid dynamics theory and the K-FWH acoustic equation,a numerical simulation is conducted to investigate the aerodynamic characteristics of high-speed pantographs.A component optimization method is proposed as a possible solution to the problemof aerodynamic drag and noise in high-speed pantographs.The results of the study indicate that the panhead,base and insulator are the main contributors to aerodynamic drag and noise in high-speed pantographs.Therefore,a gradual optimization process is implemented to improve the most significant components that cause aerodynamic drag and noise.By optimizing the cross-sectional shape of the strips and insulators,the drag and noise caused by airflow separation and vortex shedding can be reduced.The aerodynamic drag of insulator with circular cross section and strips with rectangular cross section is the largest.Ellipsifying insulators and optimizing the chamfer angle and height of the windward surface of the strips can improve the aerodynamic performance of the pantograph.In addition,the streamlined fairing attached to the base can eliminate the complex flow and shield the radiated noise.In contrast to the original pantograph design,the improved pantograph shows a 21.1%reduction in aerodynamic drag and a 1.65 dBA reduction in aerodynamic noise.

High-speed penetration of ogive-nose projectiles into thick concrete targets:Tests and a projectile nose evolution model

The majority of the projectiles used in the hypersonic penetration study are solid flat-nosed cylindrical projectiles with a diameter of less than 20 mm.This study aims to fill the gap in the experimental and analytical study of the evolution of the nose shape of larger hollow projectiles under hypersonic penetration.In the hypersonic penetration test,eight ogive-nose AerMet100 steel projectiles with a diameter of 40 mm were launched to hit concrete targets with impact velocities that ranged from 1351 to 1877 m/s.Severe erosion of the projectiles was observed during high-speed penetration of heterogeneous targets,and apparent localized mushrooming occurred in the front nose of recovered projectiles.By examining the damage to projectiles,a linear relationship was found between the relative length reduction rate and the initial kinetic energy of projectiles in different penetration tests.Furthermore,microscopic analysis revealed the forming mechanism of the localized mushrooming phenomenon for eroding penetration,i.e.,material spall erosion abrasion mechanism,material flow and redistribution abrasion mechanism and localized radial upsetting deformation mechanism.Finally,a model of highspeed penetration that included erosion was established on the basis of a model of the evolution of the projectile nose that considers radial upsetting;the model was validated by test data from the literature and the present study.Depending upon the impact velocity,v0,the projectile nose may behave as undistorted,radially distorted or hemispherical.Due to the effects of abrasion of the projectile and enhancement of radial upsetting on the duration and amplitude of the secondary rising segment in the pulse shape of projectile deceleration,the predicted DOP had an upper limit.

Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

Stress-assisted corrosion mechanism of 3Ni steel by using gradient boosting decision tree machining learning method

Traditional 3Ni weathering steel cannot completely meet the requirements for offshore engineering development,resulting in the design of novel 3Ni steel with the addition of microalloy elements such as Mn or Nb for strength enhancement becoming a trend.The stress-assisted corrosion behavior of a novel designed high-strength 3Ni steel was investigated in the current study using the corrosion big data method.The information on the corrosion process was recorded using the galvanic corrosion current monitoring method.The gradi-ent boosting decision tree(GBDT)machine learning method was used to mine the corrosion mechanism,and the importance of the struc-ture factor was investigated.Field exposure tests were conducted to verify the calculated results using the GBDT method.Results indic-ated that the GBDT method can be effectively used to study the influence of structural factors on the corrosion process of 3Ni steel.Dif-ferent mechanisms for the addition of Mn and Cu to the stress-assisted corrosion of 3Ni steel suggested that Mn and Cu have no obvious effect on the corrosion rate of non-stressed 3Ni steel during the early stage of corrosion.When the corrosion reached a stable state,the in-crease in Mn element content increased the corrosion rate of 3Ni steel,while Cu reduced this rate.In the presence of stress,the increase in Mn element content and Cu addition can inhibit the corrosion process.The corrosion law of outdoor-exposed 3Ni steel is consistent with the law based on corrosion big data technology,verifying the reliability of the big data evaluation method and data prediction model selection.

MACHINING-FEATURE BASED 3-AXIS AUTOMATIC NC PROGRAMMING FOR HIGH-SPEED MILLING

Machining-features of the workplace are described by using of the object-oriented （O-O） technology. Geometrical machining-features are recognized in the given cut region by using the maximum membership priciple about the fuzzy set. Depending on the IF-THEN rule and the fuzzy matching method, the rough information of the machining-process for high-speed milling （HSM） is extracted based on the database of machining-process for HSM. The optimization model of machining-process scheme is established to obtain shorter cut time, lower cost or higher surface quality. It is helpful to form successful cases for HSM. NC programming for HSM is realized according to optimized machining-process data from HSM cases selected by the optimization model and the extracted information of machining-process.

A review of artificial intelligence applications in high-speed railway systems

In recent years,the global surge of High-speed Railway(HSR)revolutionized ground transportation,providing secure,comfortable,and punctual services.The next-gen HSR,fueled by emerging services like video surveillance,emergency communication,and real-time scheduling,demands advanced capabilities in real-time perception,automated driving,and digitized services,which accelerate the integration and application of Artificial Intelligence(AI)in the HSR system.This paper first provides a brief overview of AI,covering its origin,evolution,and breakthrough applications.A comprehensive review is then given regarding the most advanced AI technologies and applications in three macro application domains of the HSR system:mechanical manufacturing and electrical control,communication and signal control,and transportation management.The literature is categorized and compared across nine application directions labeled as intelligent manufacturing of trains and key components,forecast of railroad maintenance,optimization of energy consumption in railroads and trains,communication security,communication dependability,channel modeling and estimation,passenger scheduling,traffic flow forecasting,high-speed railway smart platform.Finally,challenges associated with the application of AI are discussed,offering insights for future research directions.

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community:a comparative analysis

The aerospace community widely uses difficult-to-cut materials,such as titanium alloys,high-temperature alloys,metal/ceramic/polymer matrix composites,hard and brittle materials,and geometrically complex components,such as thin-walled structures,microchannels,and complex surfaces.Mechanical machining is the main material removal process for the vast majority of aerospace components.However,many problems exist,including severe and rapid tool wear,low machining efficiency,and poor surface integrity.Nontraditional energy-assisted mechanical machining is a hybrid process that uses nontraditional energies(vibration,laser,electricity,etc)to improve the machinability of local materials and decrease the burden of mechanical machining.This provides a feasible and promising method to improve the material removal rate and surface quality,reduce process forces,and prolong tool life.However,systematic reviews of this technology are lacking with respect to the current research status and development direction.This paper reviews the recent progress in the nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in the aerospace community.In addition,this paper focuses on the processing principles,material responses under nontraditional energy,resultant forces and temperatures,material removal mechanisms,and applications of these processes,including vibration-,laser-,electric-,magnetic-,chemical-,advanced coolant-,and hybrid nontraditional energy-assisted mechanical machining.Finally,a comprehensive summary of the principles,advantages,and limitations of each hybrid process is provided,and future perspectives on forward design,device development,and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

Human intrusion detection for high-speed railway perimeter under all-weather condition

Purpose – The paper aims to solve the problem of personnel intrusion identification within the limits of highspeed railways. It adopts the fusion method of millimeter wave radar and camera to improve the accuracy ofobject recognition in dark and harsh weather conditions.Design/methodology/approach – This paper adopts the fusion strategy of radar and camera linkage toachieve focus amplification of long-distance targets and solves the problem of low illumination by laser lightfilling of the focus point. In order to improve the recognition effect, this paper adopts the YOLOv8 algorithm formulti-scale target recognition. In addition, for the image distortion caused by bad weather, this paper proposesa linkage and tracking fusion strategy to output the correct alarm results.Findings – Simulated intrusion tests show that the proposed method can effectively detect human intrusionwithin 0–200 m during the day and night in sunny weather and can achieve more than 80% recognitionaccuracy for extreme severe weather conditions.Originality/value – (1) The authors propose a personnel intrusion monitoring scheme based on the fusion ofmillimeter wave radar and camera, achieving all-weather intrusion monitoring;(2) The authors propose a newmulti-level fusion algorithm based on linkage and tracking to achieve intrusion target monitoring underadverse weather conditions;(3) The authors have conducted a large number of innovative simulationexperiments to verify the effectiveness of the method proposed in this article.

Atomic-scale dissecting the formation mechanism of gradient nanostructured layer on Mg alloy processed by a novel high-speed machining technique

Severe plastic deformation(SPD)-induced gradient nanostructured(GNS)metallic materials exhibit superior mechanical performance,especially the high strength and good ductility.In this study,a novel high-speed machining SPD technique,namely single point diamond turning(SPDT),was developed to produce effectively the GNS layer on the hexagonal close-packed(HCP)structural Mg alloy.The high-resolution transmission electron microscopy observations and atomistic molecular dynamics simulations were mainly performed to atomic-scale dissect the grain refinement process and corresponding plastic deformation mechanisms of the GNS layer.It was found that the grain refinement process for the formation of the GNS Mg alloy layer consists of elongated coarse grains,lamellar fine grains with deformation-induced-tension twins and contraction twins,ultrafine grains,and nanograins with the grain size of~70 nm along the direction from the inner matrix to surface.Specifically,experiment results and atomistic simulations reveal that these deformation twins are formed by gliding twinning partial dislocations that are dissociated from the lattice dislocations piled up at grain boundaries.The corresponding deformation mechanisms were evidenced to transit from the deformation twinning to dislocation slip when the grain size was below 2.45μm.Moreover,the Hall-Petch relationship plot and the surface equivalent stress along the gradient direction estimated by finite element analysis for the SPDT process were incorporated to quantitatively elucidate the transition of defo rmation mechanisms during the grain refinement process.Our findings have implications for the development of the facile SPD technique to construct high strength-ductility heterogeneous GNS metals,especially for the HCP metals.

Tool-path planning for free-form surface high-speed high-resolution machining using torus cutter

In CNC machining, two essential components decide the accuracy and machining time for a sculptured surface: one is the step-size interval, the other is the tool-path interval. Due to the limitation of the conventional method for calculating the tool-path interval, it cannot satisfy the machining requirement for high-speed and high-resolution machining. Accordingly, for high-speed and high-resolution machining, the current study proposes a new tool-path interval algorithm, plus a variable step-size algorithm for NURBS. Furthermore, a new type cutter, which can improve the cutting efficiency, is investigated in the paper. The transversal equation of the torus cutter onto the flat plan is given in this paper. The tool-path interval is calculated with the transversal equation and the proposed algorithm. The illustrated example shows that the redundant tool paths can be reduced because an accurate tool-path interval could be calculated.

A discussion about the limitations of the Eurocode’s high-speed load model for railway bridges

High-speed railway bridges are subjected to normative limitations concerning maximum permissible deck accelerations.For the design of these structures,the European norm EN 1991-2 introduces the high-speed load model(HSLM)—a set of point loads intended to include the effects of existing high-speed trains.Yet,the evolution of current trains and the recent development of new load models motivate a discussion regarding the limits of validity of the HSLM.For this study,a large number of randomly generated load models of articulated,conventional,and regular trains are tested and compared with the envelope of HSLM effects.For each type of train,two sets of 100,000 load models are considered:one abiding by the limits of the EN 1991-2 and another considering wider limits.This comparison is achieved using both a bridge-independent metric(train signatures)and dynamic analyses on a case study bridge(the Canelas bridge of the Portuguese Railway Network).For the latter,a methodology to decrease the computational cost of moving loads analysis is introduced.Results show that some theoretical load models constructed within the stipulated limits of the norm can lead to effects not covered by the HSLM.This is especially noted in conventional trains,where there is a relation with larger distances between centres of adjacent vehicle bogies.

Numerical investigation of friction-heating-pressurization and its control parameters in the shear band of high-speed landslides

High-speed sliding often leads to catastrophic landslides,many of which,in the initial sliding phase before disintegration,experience a friction-induced thermal pressurization effect in the bottom shear band,accelerating the movement of the overlying sliding mass.To quantitatively investigate this complex multiphysical phenomenon,we established a set of equations that describe the variations in temperature and excess pore pressure within the shear band,as well as the conservation of momentum equation for the overlying sliding mass.With a simplified landslide model,we investigated the variations of temperature and excess pore pressure within the shear band and their impacts on the velocity of the overlying sliding mass.On this basis,we studied the impact of seven key parameters on the maximum temperature and excess pore pressure in the shear band,as well as the impact on the velocity of the overlying sliding mass.The simulation results of the standard model show that the temperature and excess pore pressure in the shear band are significantly higher than those in the adjacent areas,and reach the maximum values in the center.Within a few seconds after the start,the maximum excess pore pressure in the shear zone is close to the initial stress,and the shear strength loss rate exceeds 90%.The thermal pressurization mechanism significantly increases the velocity of the overlying sliding mass.The results of parameter sensitivity analysis show that the thermal expansion coefficient has the most significant impact on the temperature and excess pore pressure in the shear band,and the sliding surface dip angle has the most significant impact on the velocity of the overlying sliding mass.The results of this study are of great significance for clarifying the mechanism of thermal pressurization-induced high-speed sliding.

Numerical investigation on the aerodynamic drag reduction based on bottom deflectors and streamlined bogies of a high-speed train

The complex structure of the bottom of a high-speed train is an important source of train aerodynamic drag.Thus,improving the bottom structure is of great significance to reduce the aerodynamic drag of the train.In this study,computational fluid dynamics(CFD)based on three-dimensional steady incompressible Reynolds-average Naiver-Stokes(RANS)equations and Realizable k-ε turbulence model were utilized for numerical simulations.Inspired by the concept of streamlined design and the idea of bottom flow field control,this study iteratively designed the bogies in a streamlined shape and combined them with the bottom deflectors to investigate the joint drag reduction mechanism.Three models,i.e.,single-bogie model,simplified train model,and eight-car high-speed train model,were created and their aerodynamic characteristics were analyzed.The results show that the single-bogie model with streamlined design shows a noticeable drag reduction,whose power bogie and trailer bogie experience 13.92%and 7.63%drag reduction,respectively.The range of positive pressure area on the bogie is reduced.The aerodynamic drag can be further reduced to 15.01%by installing both the streamlined bogie and the deflector on the simplified train model.When the streamlined bogies and deflectors are used on the eight-car model together,the total drag reduction rate reaches 2.90%.Therefore,the proposed aerodynamic kit for the high-speed train bottom is capable to improve the flow structure around the bogie regions,reduce the bottom flow velocity,and narrow the scope of the train’s influence on the surrounding environment,achieving the appreciable reduction of aerodynamic drag.This paper can provide a new idea for the drag reduction of high-speed trains.

Torque effect on vibration behavior of high-speed train gearbox under internal and external excitations

The high-speed train transmission system,experiencing both the internal excitation originating from gear meshing and the external excitation originating from the wheel-rail interaction,exhibits complex dynamic behavior in the actual service environment.This paper focuses on the gearbox in the high-speed train to carry out the bench test,in which various operat-ing conditions(torques and rotation speeds)were set up and the excitation condition covering both internal and external was created.Acceleration responses on multiple positions of the gearbox were acquired in the test and the vibration behavior of the gearbox was studied.Meanwhile,a stochastic excitation modal test was also carried out on the test bench under different torques,and the modal parameter of the gearbox was identified.Finally,the sweep frequency response of the gearbox under gear meshing excitation was analyzed through dynamic modeling.The results showed that the torque has an attenuating effect on the amplitude of gear meshing frequency on the gearbox,and the effect of external excitation on the gearbox vibration cannot be ignored,especially under the rated operating condition.It was also found that the torque affects the modal param-eter of the gearbox significantly.The torque has a great effect on both the gear meshing stiffness and the bearing stiffness in the transmission system,which is the inherent reason for the changed modal characteristics observed in the modal test and affects the vibration behavior of the gearbox consequently.